Modular bridgeless thermal envelope for prefabricated construction

ABSTRACT

This application relates to methods of manufacturing a modular thermal envelope. The modular thermal envelope includes an internal structural frame. The modular thermal envelope further includes a non-structural insulated laminated wall panel. The modular thermal envelope further includes a bent clip. An example of a bent clip is a steel clip including a first portion welded to the structural interior frame element, a bent portion that defines a gap between the structural interior frame element, and a second portion of the bent clip. The modular thermal envelope has the non-structural insulated laminated wall panel positioned between the structural interior frame element and the second portion of the bent clip. The modular thermal envelope further is substantially weatherproof and airtight.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/771,499, filed on Nov. 26, 2018, entitled “PREFABRICATED CONSTRUCTIONCOMPRISING MODULAR STRUCTURAL FRAMEWORK CLAD WITH STRUCTURAL INSULATEDPANELS,” the entire disclosure of which is hereby incorporated byreference for all purposes.

TECHNICAL FIELD

This disclosure relates generally to the field of thermal envelopes forresidential construction. More specifically, this disclosure relates toforming a thermal envelope with an internal structural frame and using aclip to attach a non-structural panel.

BACKGROUND

The benefits of prefabricated modular construction, as compared totraditional site-built construction, have been known for many years.These advantages include, but are not limited to, greater qualitycontrol, faster construction time, reduced materials and labor, moreprecise construction techniques, reduced cost, and higher performancebuilding envelopes. While most prefabricated construction relies on woodframing for the structure, some modular building manufacturers aretransitioning to the use of a steel frame as the structural frameworkfor individual modules. This is due to the increased structural strengthcompared to wood, allowing for more architecturally challenging designsas well as taller structures with more stories.

Additionally, the steel frame creates a rigid substrate resistingdeformation during shipment to the site, maximizing the number ofadditional layers of building components and materials that can beapplied in-factory with minimal concern for damage or separation atseams, allowing for a greater percentage of the final building design tobe assembled in the factory. Conventional framing methods are used inconjunction with the structural steel frame to complete the remainder ofthe building envelope walls, resulting in the framed walls beingconstructed in plane with the steel structure.

Another alternative to wood or steel, some prefabricated constructionmethods rely on structural insulated panels (SIPs) to form thestructural framing. The benefits of SIPs, as compared to stick-builtconstruction, have also been known for decades. These advantages includegreater ease and speed of construction, greater airtightness, fewerthermal-bridges, greater strength, and greater resistance to mold andmildew. The most common method of constructing using SIPs is tofabricate the sandwich panels at a factory using wood for the skins,after which they are shipped to the site and assembled on-site by a teamof contractors. Upon completion of assembling the SIPs on-site, theextent of construction completion is comparable to the framing,sheathing, and insulation of conventional stick-built construction. Aswith stick-built construction, there are still many steps required toachieve exterior waterproofing and finishes, as well as interiorfinishes.

There are some SIPs that use metal skins, which can provide aweather-tight (i.e., watertight, airtight, etc.) envelope and a finishedsurface upon assembly, requiring no further steps to complete theconstruction of the envelope. These metal-skin SIPs are installedon-site by fitting one panel into the next through an interlockingshaped tab system. In most cases, simple, small structures can rely onthe structural integrity of the SIP panels alone. On larger or morecomplex structures, additional structural framework is required. In suchcases, with wood-skin panels, the additional structure is commonlylocated in-plane with the insulation layer between the wood skins,whereas metal skinned panels are fastened outboard of a structuralframework as with a cladding.

While current practices in the areas of prefabricated modularconstruction and SIPs construction have offered many advancements to theconstruction industry as noted above, there are still significantproblems and limitations that can be improved upon.

As mentioned above, manufacturers of prefabricated buildings who use asteel frame as the structure, rely upon conventional wall framingtechniques to complete the exterior building envelope. Conventional wallframing requires many steps to complete, requiring far more labor andmaterial than SIPs construction. It also results in many more seams andfasteners resulting is a less air-tight envelope, which reduces energyefficiency, as well as introducing small openings which can allow formoisture migration through the wall and condensation within the wallwhich can lead to mold growth. Finally, conventional wall framingintroduces thermal bridges at every stud location reducing the thermalperformance of the wall.

In addition to the drawbacks of using conventional wall framing, thewall framing is installed in plane with the steel frame resulting insubstantial thermal bridges where the steel occupies the wall cavity.This significantly reduces the thermal performance of the wall and canintroduce condensation.

As mentioned above, there are two main classifications of SIP wallconstruction. The most common uses wood skins applied to a rigid foamcore. While this method allows for the flexibility to achieve a finishedlook similar to other conventional construction methods through theapplication of additional layers of material on either side, it does notbenefit from the material and labor efficiency of the simplified3-component wall system of metal skin SIPs, which require no furthermaterial application beyond the SIP panel itself. Conversely, whilemetal skin SIP panels offer greater material and labor efficiencies,they are limited in their aesthetic optionality, and the cold metalsurfaces do not result in a comfortable environment for inhabitants.Consequently, metal SIPs are generally limited to use in industrialbuildings. Metal SIPs are also limited in their design options andcustomizability because of their connection methods, and they can beprone to scratching, denting and rusting in coastal areas.

SUMMARY

The current disclosure draws on the principles of prefabricatedconstruction and non-structural insulated laminated panel constructionto produce a new thermal envelope with an internal structural frame.

The combination of the rigid internal structural frame and finishednon-structural insulated panel (NSIP) wall system to produce a strong,yet light construction which is able to resist or minimize the effectsof hurricanes, seismic forces, and other environmental events whileremaining light enough to be easily transported. The rigid internalstructural frame and bonded wall panels also allow for the constructionto be fully completed in the factory without concern of transportationdamage due to a weak structure, and minimizing the need for site-basedwork to complete the construction, thereby lowering costs and reducingconstruction time.

Simplified wall assembly keeps cost and construction time down, allowingfor the use of commercial-grade maintenance-free sheet materials whilereducing cost compared to lesser site-built materials and methods.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of variousembodiments may be realized by reference to the following figures. Inthe appended figures, similar components or features may have the samereference label. Further, various components of the same type may bedistinguished by following the reference label by a dash and a secondlabel that distinguishes among the similar components. If only the firstreference label is used in the specification, the description isapplicable to any one of the similar components having the same firstreference label irrespective of the second reference label.

FIG. 1 illustrates a thermal envelope with an internal structural frame,according to exemplary embodiments of the present disclosure.

FIG. 2 illustrates component members of the internal structural frame,according to exemplary embodiments of the present disclosure.

FIG. 3 illustrates a sectional view of a thermal envelope with aninternal structural frame, according to exemplary embodiments of thepresent disclosure.

FIG. 4, comprising FIG. 4A and FIG. 4B, illustrates sectional views of aroof and wall connection, according to exemplary embodiments of thepresent disclosure.

FIG. 5 illustrates a sectional view of a floor and wall connection ofthe thermal envelope, according to exemplary embodiments of the presentdisclosure.

FIG. 6, comprising FIG. 6A and FIG. 6B, illustrates sectional views of ajunction between non-structural insulated laminated wall panels,according to exemplary embodiments of the present disclosure.

FIG. 7 illustrates a process of manufacturing a thermal envelope with aninternal structural frame, according to exemplary embodiments of thepresent disclosure.

DETAILED DESCRIPTION

Briefly described, the present disclosure pertains to variousconfigurations of a steel-framed modular unit framework clad withnon-structural insulated laminated panels to achieve a finished wall,for the construction of building structures.

In a non-limiting example, a thermal envelope is created throughassembly of a plurality of manufactured components. The thermal envelopeincludes a structural interior frame. The structural interior frame isenveloped by non-structural insulated laminated wall panels. In someembodiments, each NSIP is coupled to the structural interior frame byway of bent clips. An example of a bent clip is a steel clip including afirst portion welded to the structural interior frame element, a bentportion that defines a gap between the structural interior frameelement, and a second portion of the bent clip. The non-structuralinsulated laminated wall panel includes a recessed cutaway that ispositioned between the structural interior frame element and the secondportion of the bent clip, so as to fasten the NSIP to the structuralinterior frame. A sealing strip may be attached to the NSIP andpositioned in the recessed cutaway to further seal the thermal envelopeat the junction between two NSIPs. Examples of the sealing strip myinclude vapor tape, SIP tape, or the like.

As used herein, interior means facing towards the interior of theenclosed structure, horizontal means substantially parallel to a groundsurface, vertical means substantially perpendicular to the groundsurface, lateral means an orientation that is non-vertical and includeshorizontal, exterior means facing towards the exterior of the thermalenvelope.

Referring now to the figures, FIG. 1 illustrates a thermal envelope 100with an internal structural frame, according to the present disclosure.An example of the thermal envelope 100 is a combination of wall panels,roof panels, floor panels that limit or prevent heat transfer from aninterior section (e.g., inside the thermal envelope) to an exteriorsection (e.g., the outside of the thermal envelope) and vice versa.

As illustrated by FIG. 1, the thermal envelope 100 includes multiplenon-structural insulated laminated wall panels 102, an insulated roofpanel 106, additional wall panels 104, window panels 108, and aninternal structural frame (obscured by the exterior skin of the variouspanels). It should be understood that additional wall panels 104 are ofa similar design as non-structural insulated laminated wall panel 102,the additional wall panels 104 are modified for each thermal envelope toaccommodate other features such as window panels, or other architecturalfeatures. The example shown in FIG. 1 does not show a door, but ofcourse a door or some other entry way is provided in preferredembodiments and can be attached to the NSIP wall panels 102 in the samemanner as window panels 108 are connected to NSIP wall panels 102. Theinterior structural frame, which is shown in and described in moredetail with respect to other figures, is constructed in certainembodiments using a number of substantially horizontal and verticalbeams to form an enclosure. An example of a non-structural insulatedlaminated wall panel 102 NSIP has an exterior panel and interior panelthat sandwich an insulation layer. The interior and exterior panels maybe finished with various types of laminates, or other veneer, etc. foraesthetic purposes. For clarity of explanation, the internal structuralframe e.g., a steel frame as depicted in FIG. 2 bears the structuralload of the thermal envelope 100 and the non-structural insulatedlaminated wall panel 102 bears only a transverse load, such as a windforce.

For example, the thermal envelope 100 is created by attaching one ormore NSIPs to the exterior side of the beams comprising the internalstructural frame. The NSIP preferably comprise a simplified 3-componentsystem having an interior skin, rigid insulation, and exterior skin. Insome instances, the internal structural frame is formed by metal, suchas steel or any other sufficiently strong and preferably non-corrosivemetal. The NSIP panels are attached to the metal frame using a series ofbent clips (obscured in FIG. 1). The bent clips may be welded orotherwise fixedly secured to the outside, i.e., exterior side, of eachof the horizontal, lateral or vertical beams of the internal structuralframe (i.e. FIG. 2 showing the bent clips welded to the horizontal andlateral beams, providing a binding mechanism for the NSIPs to beremovably attached to the internal structural frame. As explained below,a portion of the NSIP, formed by way of a recessed cut-away, is slidunder the non-welded end of the bent clip, which provides a snug fit andleaves no gap that would allow outside air to penetrate the thermalenvelope 100. Attaching the NSIPs to the internal structural frame suchthat each NSIP is exterior to the internal structural frame keeps theentirety of the internal structural frame inside of the thermal envelope100. The configuration of the internal structural frame inside thethermal envelope increases airtightness, improves thermal efficiency,eliminates detrimental thermal bridges (e.g., fasteners penetrating theinsulation of the thermal envelope), and reduces a potential for watercondensation within the wall. The use of the bent clips improvesassembly speeds and eliminates the need for manually applied fastenersto bind the NSIPs to the internal structural frame. The internalstructural frame bears the structural load, leaving only transverseloads (e.g., wind loads) to be handled by the NSIP wall panels 102,window panels 108, and other non-load bearing elements such as a door,which allows for greater design flexibility and larger wall openings.

FIG. 2 illustrates component members of the internal structural frame200, according to the present disclosure. The internal structural frame200 is 3 dimensional frame formed of various vertical and horizontalmembers that are connected in a particular configuration that providesload bearing for the thermal envelope 100.

For instance, the internal structural frame 200 includes a first tophorizontal member 202A that is coupled to a first vertical member 204Aon a first end of the first top horizontal member 202A and a secondvertical member 204B at the second end of the first top horizontalmember 202A. The first vertical member 204A and the second verticalmember 204B are connected to a bottom horizontal member 210A at oppositeends. The first top horizontal member 202A is additionally coupled to afirst lateral member 206A that connects to a second top horizontalmember 202B. The first top horizontal member 202A is additionallycoupled to a second lateral member 206B that connects to a second tophorizontal member 202B. The bottom horizontal member 210A isadditionally coupled to a third lateral member 206C and a fourth lateralmember 206D, which is connected to a second bottom horizontal member210B. The internal structural frame 200 is a load-bearing structuralframe that can be stacked or coupled to an additional internalstructural frame depending on the size of the thermal envelope 100. Themembers of the internal structural frame 200 can be coupled to eachother in any known manner, such as by welding or bolting the memberstogether. Vertical and horizontal member components of the interiorstructural frame may be configured to form a substantially rectangularshape. However, at least some of the member components may also and/oralternatively be arranged diagonally or in other configurations toprovide other frame shapes.

In an alternative embodiment, vertical members 204C and 204D may bedifferent heights than vertical members 204A and 204B. A roof clip 212attaches the roof non-structural laminated insulated panel at an angleas described and likely best understood with regard to FIG. 4.

The one or more bent clips 208 are coupled to the internal structuralframe 200 and used to attach the non-structural insulated laminated wallpanel to the internal structural frame 200. In one example, bent clips208 can be attached to each of top horizontal members 202A-2B, bottomhorizontal members 210A-B, lateral members 206A-D. In one example, aclip 208 has a first portion that is welded to the respective structuralmember, a second portion that is bent to define a gap between a thirdportion of the bent clip 208 and the respective structural member. Thesecond portion of the bent clip 208 may be bent at various angles andcreate different sized gaps as determined by the specific design for thethermal envelope 100. Additional details of the bent clips are likelybest understood with regard to FIGS. 3-5.

The internal structural frame may include mounting brackets 214 forsecuring the internal structural frame to a floor slab. In someconfigurations, mounting brackets 214 include a bolt, securing nut, andare welded to the respective vertical or lateral member of the internalstructural frame 200. The internal structural frame 200 and the variousvertical members and horizontal members may be made of iron, steel(e.g., stainless steel), aluminum, carbon fiber, or other suitable loadbearing materials, or combination(s) thereof. The bent clips 208 mayalso be made of iron, steel (e.g., stainless steel), aluminum, carbonfiber, or other suitable materials for securing a load bearingstructural frame to non-structural panels. Ideally, but not necessarily,the material(s) used to create the internal structural frame 200 and thebent clips 208 is or are resistant to rust. In some examples, a secondinternal structural frame may be stacked or positioned adjacent to theinternal structural frame 200. Each internal structural frame may beused as a modular component for combining to create different thermalenvelopes.

In an embodiment with stacked internal structural frames, the secondinternal structural frame may be positioned on top of the first internalstructural frame to construct a modular thermal envelop that is tallerthan a modular thermal structure with a single internal structuralframe. In an alternative embodiment with adjacent internal structuralframes, the second internal structural frame may be positioned next tothe first internal structural frame to construct a modular thermalenvelop that is wider/longer than a modular thermal structure with asingle internal structural frame. In either stacked or adjacentconfigurations, internal walls (and/or ceiling/floor) at the abutment ofthe frames may or may not be present. One of skill in the art wouldunderstand the many alternatives and structural variations of modularconstruction.

FIG. 3 illustrates a sectional view of a thermal envelope 300 with aninternal structural frame, according to an embodiment of the presentdisclosure. While FIG. 3 illustrates a sectional portion of the thermalenvelope 300, the thermal envelope 300 is formed (as shown in FIG. 1) bythe connection of a first non-structural insulated laminated wall panel302 and a roof non-structural insulated laminated panel 304. Theinternal structural frame 306 is positioned entirely within the thermalenvelope 300. Corresponding connections between an additionalnon-structural insulated laminated wall panel 302 and an additional roofnon-structural insulated laminated panel 304 form the thermal envelope300 that is cutaway to show the sectional view. Accordingly, theinternal structural frame 306 is entirely enclosed within the thermalenvelope 300. The internal structural frame 306 may be coupled to anon-structural insulated laminated wall panel 302 (including an interiorskin 312A and exterior skin 312B). Examples of the interior skin 312A orthe exterior skin 312B includes high pressure laminate (HPL) by a bentclip 308. The bent clip 308 may have a first portion welded to theinternal structural frame 306 while a second portion forms a gap betweenthe bent clip 308 and the internal structural frame 306. Thenon-structural insulated laminated wall panel 302 is secured in the gapbetween the internal structural frame 306 and the bent clip 308. In oneexample, cutaway may be created in the NSIP 302 by way of precisioncutting (e.g., hot wire cutting of the insulated core). As better shownin FIG. 4, the cutaway results in a tab-like structure on the interiorskin 312A of the NSIP 302. This tab-like structure is the portion of theNSIP 302 that is secured in the gap between the internal structuralframe 306 and the bent clip 308. The bent clip 308 may be formed fromsteel or another metal and welded the metal frame, to attach thenon-structural insulated laminated wall panel to the structural framequickly, strongly, and without the use of manually applied fastenerswhich compromise the integrity of the thermal envelope 300.

As illustrated in FIG. 3, the internal structural frame 306 includes aroof clip 314. The roof clip 314 may be similar to bent clip 308, butmay be modified to have an angled portion. The angled portion of roofclip 314 may be formed such that the angled portion sets a slope of theroof non-structural insulated laminated panel 304. Additionaldescription of the roof clip is described with regard to FIGS. 4A and4B. The roof non-structural insulated laminated panel 304 may includemultiple layers and in some cases, includes an exterior finishedsurface, interior finished surface, and additional layers. However, inother examples, the roof non-structural insulated laminated panelprovides a substantially waterproof and airtight thermal envelopewithout requiring additional layers.

The thermal envelope 300 can also include a non-structural insulatedpanel strip (NSIP strip) positioned between a first non-structuralinsulated laminated wall panel 304 and an additional non-structuralinsulated laminated wall panel 304, a window panel 316, a door panel(not shown), or other components of the thermal envelope. A first NSIPstrip 310A may be positioned in a cut-out or groove of thenon-structural insulated laminated wall panel 304. A second NSIP strip310A may be positioned in a cut-out or groove of the non-structuralinsulated laminated wall panel 304. The first NSIP strip 310 and thesecond NSIP strip 310B are precisely fitted using machined tolerancesthat allow the installation of the NSIP strips 310A and 310B to besubstantially waterproof and airtight. The NSIP strips 310A and 310Bseal any gap between adjacent non-structural insulated laminated wallpanels, adjacent window panels, or other junctions of the thermalenvelope. The precision fitting means that any mechanical fasteners arenot necessary for the structure of the thermal envelope 300. Fabricatingthe thermal envelope without mechanical fasteners yields a “bridgeless”thermal envelope 300 that is free of mechanical thermal bridges thatwould penetrate into the thermal envelope 300.

For example, the non-structural insulated laminated wall panel is formedfrom precision fabrication of the rigid foam core. In some embodiments,the precise fabrication involves using a hot wire cutter to createprecisely formed voids (obscured in FIG. 3) and slots in the SIP panelsthat allow the SIP panels to be attached to the metal frame, and to eachother. The precise tolerances, which in some embodiments may be between1/32″- 1/64″, achieved through computer-controlled, factory-basedfabrication and assembly are necessary for realizing the full benefitsdisclosed herein. For example, precisely-sized parallel voids cut intothe top surface of the rigid foam core of each NSIP 302 creates a thinvertical structure that fits precisely under the bent clip 308. Slotsformed into the vertical edges of the NSIP walls 302 allow the NSIPstrips 310A and 310B to be inserted into the vertical edges of adjacentNSIP walls 302, and/or NSIP walls 302 and adjacent window members 316.The precision fit of the voids in the rigid foam to the bent clips andNSIP and window NSIP strips 310 (e.g., a NSIP strip modified to fit to awindow frame) allows for a strong, airtight, and watertight connectionthroughout the thermal envelope 100. In some cases, a frame of thewindow may include a bent clip for coupling the NSIP walls 302. In someexamples, an adhesive may be used at the connections of the NSIP strips310 to the non-structural insulated laminated wall panel 304 toeliminate the need for fasteners at the adjacent NSIP connection,resulting thermal envelope 100, which can be continuous and monolithic.In some embodiments, the bent clip 308 may be used in a similar way tosecure decorative features to an interior of the internal structuralframe to obscure the internal structural frame from visual observationfrom inside the thermal envelope.

The fabrication method of the non-structural insulated laminated wallpanels 302 allows for the use of any sheet material that possesses thenecessary strength and weather-resistant properties to serve as theexterior and interior skins. The fabrication method thus allows a widerange of products and architectural aesthetics including, but notlimited to, high pressure laminates, cement fiber panels, porcelainsheets, fiberglass composites, metal, wood composites, and ceramics. Theuse of precisely fabricated voids and fit of the NSIPs at the adjacentNSIP connection creates an attractive, clean-lined architectural detailknown as a “reveal”, which is usually prohibitively complicated toimplement using site-built construction methods, but is available withthis method of prefabricated construction. The result is a finished wallstem that achieves high-end construction details, paired withhigh-quality, maintenance free, commercial grade materials, at afraction of the cost of conventional construction by using a simplified3-part assembly that produces superior results.

FIG. 4A illustrates an expanded sectional view of a roof and wallconnection that forms one edge of the thermal envelope 100.

For example, a bent clip 308 is attached to the internal structuralframe 306. The bent clip 308 may have a first portion welded to theexterior side 309 of the internal structural frame 306 while anotherportion forms a gap between the bent clip 308 and the internalstructural frame 306. As shown, in one example, the first portion of thebent clip 308 may be is parallel to and welded to the exterior side 309of the structural frame 306. The second portion of the bent clip 309 maybe below the first portion and may extend perpendicular or substantiallyperpendicular to the exterior side 309 of the structural frame 306 andmay then be bent downward so as to again be parallel or substantially tothe exterior side 309, thus forming the aforementioned gap. Otherconfigurations of the bent clip 308 are possible. For example, the firstportion of the bent clip 308 may be below the perpendicular section ofthe second portion. In one example, a slot 307 is cut into the NSIP wall302 such that the interior panel (e.g., the interior skin 312A) of theNSIP wall 302 fits into the gap between the internal structural frame306 and the bent clip 308. In some embodiments, materials other than HPLmay be used for the interior skin 312A or exterior skin 312B of theNSIP. The roof clip 314 is a similar bent clip that may be angled at anysuitable angle for an architectural roofing plan. The roof clip 314secures the roof non-structural insulated laminated panel 304 to the topof each non-structural insulated laminated wall panel 302. In someembodiments, the roof non-structural insulated laminated panel 304 haveprecision gaps cut into the foam core to fit the roof clip 314. The roofclip 314 can also include an angled bracket that provides an angularoffset from the internal structural frame 306 to provide a roof angle.The roof may include multiple roof non-structural insulated laminatedpanels 304.

FIG. 4B illustrates a completed sectional view roof and wall connection,according to the present disclosure. The internal structural frame 306is illustrated inside the edge of the thermal envelope formed by roofnon-structural insulated laminated panel 304 to the non-structuralinsulated laminated wall panel 302. The bent clip 308 secures thenon-structural insulated laminated wall panel 302 to the internalstructural frame 306.

FIG. 5 illustrates a sectional view of a floor and wall connection ofthe thermal envelope, according to the present disclosure. The sectionalview includes a non-structural insulated laminated wall panel 302, amounting bracket 502, a grounding bolt 504, a securing nut 506, a floor508, and a ground environment 510.

For example, the non-structural insulated laminated wall panel 302 issecured to the floor 508 by a mounting bracket 502. The non-structuralinsulated laminated wall panel 302 is secured into position bymechanical cooperation of the mounting bracket 502, the grounding boltthat passes through an opening in the mounting bracket and penetratesinto the floor 508. In one example, the floor 508 may be concrete and ispoured over the grounding bolt 504. The grounding bolt is fixed intoposition by securing nut 506 threaded onto the grounding bolt until thebottom face of the mounting bracket is flush against the floor 508. Insome embodiments, various electrical, plumbing and other conduits may beformed or otherwise provided in the floor 508 for running wires andplumbing within the structure and awithout compromising the thermalenvelope 100.

FIGS. 6A and 6B illustrate a junction between non-structural insulatedlaminated wall panels including a NSIP strip. The junction includes afirst non-structural insulated laminated wall panel, a NSIP strip, and asecond non-structural insulated laminated wall panel. As illustrated byFIG. 4A, more than one NSIP strip can be utilized at each junction(e.g., the exterior skin and interior skin may each have an NSIP strip).

FIG. 6A illustrates an expanded sectional view of a junction betweennon-structural insulated laminated wall panels, according to the presentdisclosure. The first non-structural insulated laminated wall panel 602has an exterior groove 604 and an interior groove 606 that are preciselycut into the rigid foam insulation to accommodate an exterior NSIP strip608 and an interior NSIP strip 610. The second non-structural insulatedlaminated wall panel 612 also has an exterior groove 604 and an interiorgroove 606. The exterior NSIP strip 608 and the interior NSIP strip 610are precisely formed to fit into the exterior groove 604 and theinterior groove 606 respectively. Each of the NSIP strip 610, the top offirst non-structural insulated laminated wall panel 602, or the bottomof second non-structural insulated laminated wall panel 612 can haveadhesive 614 applied to further improve the quality of the junction. Insome embodiments, such an adhesive may be similarly applied at thejunction of an NSIP 302 and a bent clip 306. An example of preferredadhesives are bonding mixtures that are flexible and resilient againstmovement, temperature and moisture. Some appropriate adhesives mayinclude, glue, epoxy, and/or rubber cement. Instead of or in addition toan adhesive, caulking can be applied to seal the junctions.

FIG. 6B illustrates a completed sectional view of a junction betweennon-structural insulated laminated wall panels, according to the presentdisclosure. As compared to FIG. 6A, FIG. 6B depicts the precisionmanufacturing and tolerances of the interior groove and exterior grooveso that the NSIP strips fit tightly with minimal additional gap toensure the integrity of the thermal envelope.

FIG. 7 illustrates a process 700 of manufacturing a thermal envelopewith an internal structural frame, according to the present disclosure.

At block 702, the process 700 involves forming an internal structuralframe. The internal structural frame may be formed from steel or anotherload bearing material sufficient to support the load of the thermalenvelope. In one example, the internal structural frame is formed byfabricating vertical, horizontal, and lateral members and then securingthe members together in the desired shape of the thermal envelope. Someof the members may be diagonal to create more variety in shapes for thethermal envelope.

At block 704, the process 700 involves welding a bent clip onto theexterior and surfaces of each top and bottom horizontal members and eachrespective lateral member of the internal structural frame. Forinstance, each bent clip may be welded to the relevant member of theinternal structural frame as described with regards to FIGS. 1-6. Insome embodiments, the bent clips are steel-welded to a steel internalstructural frame, however, other methods of precision attachment bothknown and future do not depart from the teachings of the presentdisclosure.

At block 706, the process 700 involves securing NSIPs to each exteriorside of the internal structural frame using the bent clips, so as toenclose the frame. For instance, precision cuts to form voids in an NSIPcan be made to accommodate the bent clip, as previously described.

At block 708, the process 700 involves applying NSIP strips at thevertical junctions of NSIP panels. As described with regards to FIGS.1-6, NSIP strips are applied in exterior or interior groves cut into therigid foam of the NSIP panel to ensure integrity of the thermalenvelope.

Having described several example configurations, various modifications,alternative constructions, and equivalents may be used without departingfrom the spirit of the disclosure. For example, the above elements maybe components of a larger system, wherein other rules may takeprecedence over or otherwise modify the application of the invention.Also, a number of steps may be undertaken before, during, or after theabove elements are considered.

Further details of various embodiments of the invention are shown anddescribed in the attached drawings. It will be understood that the itemsand components shown in the drawings are not drawn to scale and are notmeant to convey any particular size, shape or other configurationlimitations. To the contrary, the modular components of the inventivepre-fabricated unit are fully customizable by size, shape, dimensions,orientation, and configuration, allowing for the construction ofcustomized dwellings and other structures. In addition, the materialsused for the described framing, NSIPs and other components of theinvention are described in the context of various preferred or possibleembodiments and by way of example only. Other types of materials may besubstituted in some cases, provided such materials provide the same,comparable or desired properties and benefits, such as theabove-described strength, insulation, weight, weather-resistant andaesthetic properties.

What is claimed is:
 1. A modular thermal envelope comprising: aninternal structural frame; a non-structural insulated laminated wallpanel; a bent clip comprising: a first portion welded to the internalstructural frame; a bent portion that defines a gap between the internalstructural frame and a second portion of the bent clip, wherein thenon-structural insulated laminated wall panel is positioned between theinternal structural frame and the second portion of the bent clip; andwherein the modular thermal envelope is substantially weatherproof andairtight.
 2. The modular thermal envelope of claim 1, wherein theinternal structural frame is entirely contained within a boundary of themodular thermal envelope, the boundary of the modular thermal envelopecomprising a continuous insulation layer.
 3. The modular thermalenvelope of claim 1, wherein the modular thermal envelope is thermallybridgeless.
 4. The modular thermal envelope of claim 1, furthercomprising a roof clip comprising: a first section welded to theinternal structural frame; an angled portion that defines a gap betweenthe internal structural frame and the angled portion of the roof clip,wherein the angled portion is set at an angle of an architectural roof;and wherein a roof non-structural insulated laminated wall panel ispositioned between the internal structural frame and the angled portionof the roof clip.
 5. The modular thermal envelope of claim 1, whereinthe non-structural insulated laminated wall panel comprises: a foamcore; a plurality of gaps cut into a foam core of the non-structuralinsulated laminated wall panel; and an interior skin and an exteriorskin to the foam core of the non-structural insulated laminated wallpanel, wherein the interior skin is positioned on the foam core based onlocations of the plurality of gaps.
 6. A method of manufacturing amodular thermal envelope, the method of manufacturing comprising:forming an internal structural frame; assembling a non-structuralinsulated laminated wall panel; coupling the non-structural insulatedlaminated wall panel to the internal structural frame using a bent clip,the bent clip comprising: a first portion welded to the internalstructural frame; and a bent portion that defines a gap between theinternal structural frame and a second portion of the bent clip.
 7. Themethod of manufacturing of claim 6, wherein forming the internalstructural frame comprises containing the internal structural frameentirely within a boundary of the modular thermal envelope.
 8. Themethod of manufacturing of claim 6, wherein the modular thermal envelopeincludes no thermal bridges between the internal structural frame and anexterior of the modular thermal envelope.
 9. The method of manufacturingof claim 6, further comprising securing a roof non-structural insulatedlaminated wall panel to the internal structural frame, the securingcomprising: forming a roof clip comprising: a first section welded tothe internal structural frame; an angled portion that defines a gapbetween the internal structural frame and the angled portion of the roofclip, wherein the angled portion is set at an angle of an architecturalroof; and positioning the roof non-structural insulated laminated wallpanel between the internal structural frame and the angled portion ofthe roof clip.
 10. The method of manufacturing of claim 6, whereinassembling a non-structural insulated laminated wall panel comprises:cutting a plurality of gaps into a foam core of the non-structuralinsulated laminated wall panel; and applying an interior skin and anexterior skin to the foam core of the non-structural insulated laminatedwall panel, wherein the interior skin is applied to the foam core basedon locations of the plurality of gaps.
 11. A bridgeless thermal envelopecomprising: an internal structural frame; a non-structural insulatedlaminated wall panel; a bent clip comprising: a first portion welded tothe internal structural frame; a bent portion that defines a gap betweenthe internal structural frame and a second portion of the bent clip;wherein the non-structural insulated laminated wall panel is positionedbetween the internal structural frame and the second portion of the bentclip; and wherein the bridgeless thermal envelope is substantiallyweatherproof and airtight.
 12. The bridgeless thermal envelope of claim11, wherein the internal structural frame is entirely contained within aboundary of the bridgeless thermal envelope, the boundary of thebridgeless thermal envelope comprising a continuous insulation layer.13. The bridgeless thermal envelope of claim 11, further comprising aroof clip comprising: a first section welded to the internal structuralframe; an angled portion that defines a gap between the internalstructural frame and the angled portion of the roof clip, wherein theangled portion is set at an angle of an architectural roof; and whereina roof non-structural insulated laminated wall panel is positionedbetween the internal structural frame and the angled portion of the roofclip.
 14. The bridgeless thermal envelope of claim 11, wherein thenon-structural insulated laminated wall panel comprises: a foam core; aplurality of gaps cut into a foam core of the non-structural insulatedlaminated wall panel; and an interior skin and an exterior skin to thefoam core of the non-structural insulated laminated wall panel, whereinthe interior skin is positioned on the foam core based on locations ofthe plurality of gaps.